Method of constructing a modular vehicle

ABSTRACT

A method of constructing a modular vehicle is provided. A modular vehicle includes a chassis and a plurality of docking fixtures carried by the chassis. The docking fixtures may include an electrical power connection, a fluid connection and a data communication connection. The modular vehicle may also include a plurality of modules removably connected to respective ones of the docking fixtures. The plurality of modules may include at least an energy supply module, such as a fuel cell, an energy storage module and a cooling module. At least one module may include an electrical power connection coupled to the electrical power connection of a docking fixture, at least one module may include a fluid connection coupled to the fluid connection of a docking fixture and at least one module may include a data communication connection coupled to the data communication connection of a docking fixture.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of application Ser. No. 12/563,642,filed on Sep. 21, 2009, which is hereby incorporated herein in itsentirety by reference.

TECHNOLOGICAL FIELD

Embodiments of the present disclosure relate generally to vehicles and,more particularly, to vehicles constructed in a modular fashion.

BACKGROUND

Although there are several different categories of vehicles, such aswheeled vehicles, tracked vehicles, marine vehicles and the like, withineach category, there are generally large numbers of vehicles that areidentical or nearly identical from a performance and operationalstandpoint. While the production of large numbers of identical or nearlyidentical vehicles may offer some advantages, the reliance upon largenumbers of nearly identical vehicles also brings about a number ofinefficiencies. In this regard, nearly identical vehicles may bedeployed in a number of different situations with each situationdemanding different operational characteristics from the vehicle. Sincethe nearly identical vehicles are not particularly adapted to thesituations the vehicles are to be deployed, the operationalcharacteristics of the vehicles may be somewhat mismatched to therequirements of the different deployment scenarios, thereby leading toinefficiencies.

For example, a military vehicle deployed to patrol the streets of a cityand a military vehicle deployed to tow a radar unit would be called uponto perform in different manners. In this regard, the vehicle that isdeployed to tow a radar unit would be expected to have an engine that issized and a transmission that is geared in an appropriate manner toprovide the power required to tow the radar unit. In addition, thevehicle configured to tow the radar unit may also be expected to act asa power source for the radar unit once the radar unit is deployed andoperational. However, if the vehicles that are deployed in the differentsituations are identical or nearly identical, one design approach may beto design the vehicles to satisfy the most rigorous demands placed uponthe vehicles from among all of the various situations in which thevehicles may be deployed. While a vehicle that is designed in such afashion would be expected to satisfy the operational requirements of thevarious deployment scenarios, a number of the vehicles that are deployedin some of the less demanding situations would, in effect, haveadditional and unused capacities or features, thereby resulting in aninefficient design. Alternatively, the vehicles may be designed to haveoperational characteristics that attempt to strike a balance, or, inother words, satisfy the median requirement for the various situationsin which the vehicles will be deployed. While vehicles designed in thisfashion will likely not have as many unused resources, the vehicles alsomay not be able to fully satisfy the operational characteristicsdemanded by some of the more rigorous situations in which the vehicleswill be deployed.

Vehicles, such as wheeled or tracked vehicles as well as at least somemarine vehicles, are generally constructed by initially selecting theengine and the transmission, such as by selecting a particular size ofengine and specific operational parameters for the transmission. Theremainder of the vehicle may then be assembled around the engine andtransmission. As such, the design of a vehicle may not be readily scaledso as to provide a similar vehicle of a different size. Instead, adifferent engine and transmission may need to be selected to satisfyrequirements of the differently-sized vehicle with the remainder of thedifferently-sized vehicle then again being constructed about theselected engine and transmission.

Additionally, current vehicular design generally utilizes a number ofunique interfaces between the various components with the interfacessometimes differing from one type of vehicle to another type of vehicle.As such, it may be more difficult than desired to reuse or swapcomponents between different types of vehicles. Further, a vehicledesigned about a particular engine and transmission may not be readilyaltered or upgraded to accept a different engine, such as an engineconstructed based upon improved technology. Similarly, the design ofvehicles about a particular engine and transmission may also limit theadaptability of the vehicles to the demands of the particular situationsin which the vehicles are expected to be deployed.

It may therefore be desirable to provide an improved technique for theconstruction of vehicles. For example, it may be desirable to provide animproved technique for the construction of vehicles that are morecustomized and may therefore by adapted to the demands expected to beplaced upon the vehicle once deployed.

BRIEF SUMMARY

A method of constructing a modular vehicle is provided according toembodiments of the present disclosure. By constructing the vehicle in amodular fashion, the vehicle can be more readily adapted to the demandsthat are anticipated to be placed upon the vehicle following deployment.Additionally, the modular construction of the vehicle according toembodiments of the present disclosure may facilitate the scalability ofthe vehicles by providing a more efficient mechanism for constructing avehicle of a different size. Further, the construction of a vehicleaccording to a modular concept in accordance with embodiments of thepresent disclosure may facilitate the maintainability of the vehicle bypermitting modules to be more readily replaced or swapped and mayfacilitate the subsequent insertion of different or additional modulesthat may include improvements that have been introduced since theinitial construction of the vehicle.

In one embodiment, a method of constructing a modular vehicle isprovided that includes providing a chassis that carries a plurality ofdocking fixtures. At least one of the docking fixtures includes anelectrical power connection, at least one of the fixtures includes afluid connection and at least one of the fixtures includes a datacommunication connection. The method of this embodiment also includesremovably connecting a plurality of modules to respective ones of thedocking fixtures. The plurality of modules may include at least anenergy supply module, such as a fuel cell, and an energy storage module.In order to removably connect the plurality of modules, an electricalpower connection of at least one of the modules may be coupled to theelectrical power connection of at least one docking fixture. Inaddition, a fluid connection of at least one of the modules may becoupled to the fluid connection of at least one docking fixture. Inaddition, a data communication connection of at least one of the modulesmay be coupled to the data communication connection of at least onedocking fixture.

In order to removably connect a plurality of modules to respective onesof the docking fixtures in accordance with one embodiment, the methodmay facilitate the removable connection of at least one module to arespective docking fixture with at least one guide pin. In addition toremovably connecting the energy supply module and the energy storagemodule to respective docking fixtures, the method of one embodiment mayalso couple a fluid connection of a cooling module to the fluidconnection of a respective docking fixture. Similarly, the method of oneembodiment may removably connect a crew component load and/or anexternal power consumption load to a respective docking fixture. Inaddition, the method of one embodiment may provide for sharing a commonfluid between the plurality of docking fixtures and the plurality ofmodules.

The features, functions, and advantages that have been discussed can beachieved independently and various embodiments of the present disclosuremay be combined in yet other embodiments, further details of which canbe seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described embodiments the disclosure in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is a perspective view of a modular vehicle in accordance with oneembodiment of the present disclosure;

FIG. 2 is a perspective view of the underside of the modular vehicle ofFIG. 1;

FIG. 3 is a block diagram of a plurality of docking fixtures and aplurality of modules in accordance with one embodiment of the presentdisclosure;

FIG. 4 is a block diagram of an energy supply module and an associateddocking fixture in accordance with one embodiment of the presentdisclosure;

FIG. 5A is a front view of a docking fixture for an energy supply modulein accordance with one embodiment of the present disclosure;

FIG. 5B is a side view of the docking fixture of FIG. 5A;

FIG. 5C is a side view of the docking fixture of FIGS. 5A and 5B whichillustrates its connection to an energy supply module;

FIG. 6 is a block diagram of two energy supply modules and theassociated docking fixtures that are arranged in a parallelconfiguration in accordance with one embodiment of the presentdisclosure;

FIG. 7A is front plan view of a docking fixture for an electrical supplymodule in accordance with one embodiment of the present disclosure;

FIG. 7B is a side plan view of the docking fixture of FIG. 7A;

FIG. 7C is a perspective view of a plurality of docking fixtures forrespective electrical storage modules in accordance with one embodimentof the present disclosure; and

FIG. 8 is a flowchart of the operations performed in accordance with amethod of constructing a modular vehicle in accordance with oneembodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments are shown. Indeed, these embodiments may be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will satisfy applicable legal requirements. Likenumbers refer to like elements throughout.

A modular vehicle 10 in accordance with one embodiment of the presentdisclosure is depicted in FIGS. 1 and 2. As shown, the modular vehicle10 includes a chassis 12. Although the illustrated embodiment depicts achassis 12 for a wheeled vehicle, such as a high mobility multipurposewheeled vehicle (HMMWV), the modular vehicle 10 may be any of a widevariety of other types of wheeled vehicles, including both commercialand military vehicles. In addition, the modular vehicle 10 of otherembodiments may be a tracked vehicle, such as a tank, a bulldozer orother construction or military vehicle, or a marine vehicle, such as aship. In these instances, the modular vehicle 10 would also include achassis 12, although the chassis 12 may be configured somewhatdifferently as known to those skilled in the art in order to supportother types of wheeled vehicles, or tracked or marine vehicles.

In addition to the chassis 12, the modular vehicle 10 includes aplurality of docking fixtures 14 carried by the chassis 12 as well as aplurality of modules 16 removably connected to respective ones of thedocking fixtures 14. Typically, the docking fixtures are securelyconnected to the chassis 12, such as by bolts, weldments or other typesof connectors. On the other hand, modules 16 may be plugged into orotherwise connected to the respective docking fixtures 14 in such amanner that the modules 16 may subsequently be removed without damage tothe docking fixtures 14 and generally without requiring extensive, ifany, rework or repair of the docking fixtures 14 or the modules 16.Although the modular vehicle 10 includes a plurality of modules 16, thenumber of modules and the type and mix of modules 16 may be determinedduring the design and construction of the modular vehicle 10. As such,the modular vehicle 10 may be adapted to more closely satisfy theprojected operational requirements for the modular vehicle 10 followingits deployment. For example, the plurality of modules 16 may include anenergy supply module, such as a fuel cell, a combustion generationmodule, a MICE engine or the like. Additionally, the plurality ofmodules 16 may include an energy storage module, such as one or morebatteries, e.g., LiIon batteries, and/or a cooling module, such asthermal control system. Additionally or alternatively, the modularvehicle 10 may include modules 16 comprised of a crew compartment load,an external power consumption load or other types of modules.

By way of example, the modular vehicle 10 depicted in FIGS. 1 and 2includes a pair of energy supply modules in the form of combustiongenerator modules 16 a, two or more energy storage modules in the formof lithium battery packs 16 b and an external power consumption load inthe form of an exportable power unit 20 for providing power, forexample, to various external loads, such as communications equipment,lighting or the like. Additionally, the modular vehicle 10 may includetraction motors and transmissions 22 for the front and rear axles whichmay be powered by the energy supply modules 16 a and/or the energystorage modules 16 b. Although not depicted in FIGS. 1 and 2, themodular vehicle 10 may also include various crew compartment loads, suchas a heating and air conditioning unit, a radio, windshield wipers orthe like, and/or other loads, such as actuators, e.g., electric motorsand wheels.

As will be described hereinafter, the chassis 12 of the modular vehicle10 carries docking fixtures 14 for receiving the respective modules 16and for facilitating the interconnection of the modules 16 in thedesired manner. By way of example, FIG. 3 depicts a plurality of modules16 and a plurality of associated docking fixtures 14 for interconnectingthe modules 16. In this regard, three different types of modules aredepicted, namely, an energy supply module 16 a, a high voltage (HV)power distribution unit (PDU) 16 c and a cooling module, such as athermal management system 16 d. In order to receive and appropriatelyinterconnect the various modules 16, the chassis 12, such as thatdepicted in FIGS. 1 and 2, carries a plurality of docking fixtures 14.In this embodiment, the chassis 12 carries a docking fixture 14 a tointerconnect the energy supply module 16 a with the power distributionunit 16 c in order to distribute the power generated by the energysupply module 16 a to various loads, such as crew compartment loads,external power consumption loads or other loads on or off board themodular vehicle 10. Since the energy supply module 16 a may requirecooling for improved efficiency, reduced signature or the like, thechassis 12 of this embodiment may also carry a docking fixture 14 b tointerconnect the energy supply module 16 a and the cooling module, suchas the thermal management system 16 d. Additionally, the docking fixture14 b that facilitates the connection of the energy supply module 16 aand the cooling module, such as the thermal management system 16 d, tofacilitate thermal management of the energy supply module 16 a, such asby the controlled circulation of a cooling fluid or the like through theenergy supply module 16 a in order to remove waste heat or the like.

In one embodiment as depicted in FIG. 3, each module is removablyconnected to a respective docking fixture 14, that is, the powerdistribution unit 16 c is connected to a respective docking fixture 14a, the cooling module, such as the thermal management system 16 d, isconnected to a respective docking fixture 14 b and the energy supplymodule 16 a is connected to one or more docking fixtures 14 a. Thedocking fixtures, in turn, may be interconnected, such as via wiring,conduits or the like carried by or extending through the chassis 12 inorder to interconnect the various modules 16. While the energy supplymodule 16 a may be removably connected to a single docking fixture that,in turn, is interconnected to the docking fixture 14 a of both the powerdistribution unit 16 c and the docking fixture 14 b of the coolingmodule, such as a thermal management system 16 d, the energy supplymodule 16 a may be removably connected to a pair of docking fixtures 14a, 14 b as shown in FIG. 3 with one docking fixture 14 a configured tobe interconnected to the docking fixture 14 a of the power distributionunit 16 c and the other docking fixture 14 b configured to beinterconnected with the docking fixture 14 b of the thermal managementsystem 16 d.

The modules 16 may also be connected to other components in addition toa docking fixture 14. As shown in FIG. 3, for example, the coolingmodule, such as the thermal management system 16 d, may also beconnected to a radiator 18 so as to controllably circulate the coolingfluid between the radiator 18 and the energy supply module 16 d. Inaddition to or instead of circulating coolant, other fluids may becirculated through modules 16 including, for example, fuel and/or othergaseous streams, e.g., air for combustion or exhaust air.

As illustrated in the embodiment of FIGS. 1 and 2 as well as theembodiment of FIG. 3, the modular vehicle 10 may include multiplemodules 16 of the same type. With respect to the modular vehicle 10 ofFIGS. 1 and 2, the modular vehicle 10 includes a pair of combustiongenerator modules 16 a as well as two or more battery packs 16 b.Similarly, the embodiment of FIG. 3 depicts the power distribution unit16 c being configured to separately interconnect, via respective dockingfixtures 14 a, with a pair of energy supply modules 16 a. In theembodiment in which that portion of the modular vehicle 10 depicted inFIG. 3 includes a pair of energy supply modules 16 a, a second coolingmodule, such as a second thermal management system 16 d, may also beprovided to interface, via appropriate docking fixtures 14 b, with theadditional energy supply module 16 a. In embodiments that includemultiple cooling modules, such as shown in FIG. 3, the radiator 18 maybe enlarged or an additional radiator may be provided for fluidconnection to the additional cooling module 16 a.

By facilitating the optional inclusion of multiple modules 16 of thesame type, the modular vehicle 10 of embodiments of the presentdisclosure may be more closely adapted to the anticipated performancerequirements demanded of the modular vehicle 10 once deployed. As such,a common chassis 12 may be provided, but one modular vehicle that willbe required to service relatively large power loads, such as externalpower loads, may include a number of energy supply modules 16 a,typically configured in parallel, while another modular vehicleutilizing the same type of chassis 12 but designed for use in situationsdemanding much lower power consumption may include only a single energysupply module 16 a. As such, the modular vehicle 10 of embodiments ofthe present disclosure facilitates the adaptability of the modularvehicle 10 such that resulting modular vehicles 10 more efficiently meetthe design objectives and can be more individually tailored to theirrespective deployment scenarios.

Although the modules 16 and the corresponding docking fixtures 14 willvary in construction depending upon the type of module 16 and the typeof interconnections that must be facilitated by the docking fixture 14,one example of an energy supply module 16 and an associate dockingfixture 14 is provided by FIG. 4. In this regard, the energy supplymodule 16 a includes an energy generator or storage device 30, such as acombustion generator, a fuel cell or the like. The energy generator orstorage device 30 may establish a relatively high voltage level on ahigh voltage bus 32. This high voltage bus 32 is, in turn, connected viaa fuse 34 or other protection device, to the docking fixture 14 a forfurther distribution, as described below, to various high voltage loadson or off board the modular vehicle 10. As shown, the energy generatoror storage device 30 may also include a control interface (I/F) or busmanagement system (BMS) 36 for monitoring and controlling the highvoltage bus as well as a temperature sensor 38 for monitoring thetemperature of the energy generator or storage device 30.

As depicted in FIG. 4, the energy supply module 16 a may also include aprocessor 40, such as a central processing unit (CPU). The processor 40is configured to facilitate data communication between the energy supplymodule 16 and the docking fixture 14 a and, in turn, with other modulesand/or loads with which the docking fixture 14 a communicates. As shown,for example, the processor 40 of the energy supply module 16 a mayinclude a serial interface (I/F) 42 for communicating with acorresponding serial interface (I/F) 92 of the docking fixture 14 a aswell as discrete inputs and outputs (I/O) 44 for communicating withcorresponding discrete inputs and outputs (I/O) of the docking fixture14 a. In this regard, the discrete inputs and outputs 44 may includedata provided by or to the control interface or bus management system 36and may be indicative, for example, of the status of the high voltagebus 32. The energy supply module 16 a may also include a thermalmanagement unit 46. The thermal management unit 46 may include a heatsink 48 for temporary storage of heat generated by the energy generatoror storage device 30. The thermal management unit 46 may also include atemperature sensor 50 for monitoring the temperature of the heat sink48. As shown, the temperature sensors 38, 50 of the energy generator orstorage device 30 and the thermal management unit 46 may report to theprocessor 40, such as via an analog to digital converter and multiplexer52, such that the processor 40 may monitor the temperatures sensed bythe temperature sensors 38, 50 of the energy generator or storage device30 and the thermal management unit 46 and facilitate control of therespective temperatures by means of a coolant circulated modules via thedocking fixture 14 a. In this regard, the processor 40 may provideinformation regarding the respective temperatures of the energygenerator or storage device 30 and the thermal management unit 46 to thedocking fixture 14 a, such as via the serial interface 42 and/or thediscrete inputs and outputs 44.

As also depicted in FIG. 4, the docking fixture 14 a associated with theenergy supply module 16 a may include a number of components forcommunicating with corresponding components of the energy supply module16 a and for correspondingly interconnecting the energy supply module 16a with other modules 16 and/or components of the modular vehicle 10. Inthis regard, the docking fixture 14 a is configured to receive the highvoltage output provided by the energy generator or storage device 30 ofthe energy supply module 16 a. In the illustrated embodiment, thedocking fixture 14 a includes a filter 54 for filtering the high voltagesignals provided by the energy supply module 16 a prior to providing thehigh voltage signals to a high voltage to low voltage DC/DC converter56, a solid state switch module 58 and a battery and motor interface 60.As to the high voltage to low voltage DC/DC converter 56, the highvoltage signals are converted to lower voltage signals and are provided,for example, to a power supply 62 that may supply one or more levels oflow voltage signals, such as 5 volts, 12 volts and 15 volts in theillustrated embodiment. The power supply may, in turn, provide one ormore of the lower voltages to a low voltage DC bus 64 within the dockingfixture 14 a and a low voltage DC bus 66 within the energy supply module16 a. These low voltage DC busses may then provide appropriate levels ofDC power to various components of the docking fixture 14 a and theenergy supply module 16 a. For example, the low voltage DC bus 66 of theenergy supply module 16 a may provide low voltage DC power to theprocessor 40, the thermal management unit 46 and the control interfaceor bus management system 36.

The solid state switch module 58 of the docking fixture 14 a alsoreceives the high voltage signals and provides outputs at differentcurrent levels, such as 10 amps and 50 amps in one embodiment. In thisregard, the different current levels may be provided by the solid stateswitch module 58 to a high voltage bus 68 within the docking fixture 14a. The high voltage bus 68 of the docking fixture 14 a may then providehigh voltage signals to various vehicle loads, such as the tractionmotors and transmissions 22 for the front and rear axles as shown inFIG. 2, crew compartment loads or the like. In addition, the highvoltage bus 68 may provide high voltage signals to the battery and motorinterface 60 as well as to a high voltage to low voltage battery charger70. In this regard, the high voltage to low voltage battery charger 70may serve to charge a bootstrap battery 72 which may be connected via anexternal key switch 74 to the power supply 62. The battery and motorinterface 60 of the illustrated embodiment also receives high voltagesignals via the high voltage bus 68 and, in one embodiment, also fromthe filter 54 in the form of motor power bypass signals. In addition toproviding an interface with external battery and motor(s), the batterymotor interface 60 may also include a filter, such as an electromagneticinterference filter, and soft start circuit(s). As shown in FIG. 4, thebattery motor interface 60 may be connected to one or more batteries,such as a vehicle drivetrain battery 76, and/or one or more motors, suchas one or more drivetrain motors 78, thereby providing the battery andmotors with appropriate high voltage signals.

The docking fixture 14 a may also include a thermal management unit 80including or associated with a cold plate or other heat sink 82. In theillustrated embodiments in which a cooling fluid is circulated throughthe energy supply module 16 a in order to cool the energy generator orstorage device(s) 30, the thermal management unit of the docking fixture14 a may include one or more valves 84, such as servo valves, forcontrolling the fluid flowing between an external radiator and a pump86, the heat sink 48 of the energy supply module 16 a and a cold plate82 of the docking fixture 14 a. Additionally, the thermal managementunit 80 may include a temperature sensor 88 that facilitates monitoringof the temperature of the cold plate 82 such that the valves 84 may beappropriately controlled in order to circulate a sufficient quantity ofcoolant to maintain the energy generator or storage device(s) 30 at thedesired temperature.

The docking fixture 14 a may also include a processor 90, such as acentral processing unit (CPU), for interfacing with a number of theother components. In this regard, the processor 90 may include a serialinterface (I/F) 92 and discrete inputs and outputs (I/O) 94 forfacilitating data communication with the serial interface 42 and thediscrete inputs and outputs 44, respectively, of the processor 40 of theenergy supply module 16 a. As illustrated, the discrete inputs andoutputs 94 can also communicate with the solid state switch module 58,the power supply 62 and the thermal management unit 80, such as thevalves 84, in order to appropriately control operation of thosecomponents and/or to receive feedback regarding their operation.

The docking fixture 14 a may include a data bus 96 that may be connectedto the power supply 62, the solid state switch module 58 and the thermalmanagement unit 80, such as the temperature sensor 88. The processor 90of the docking fixture 14 a may also be connected to the data bus 96and, in the illustrated embodiment, may include an analog to digital(A/D) converter and multiplexer 98 configured to interface with the databus 96. As such, the processor can receive information regarding thestatus of the various components and can provide direction to thecomponents via the data bus 96 and/or the discrete inputs and outputs94. The processor 90 of the docking fixture 14 a may also include abattery port 100 for communicating with the off board vehicle batteries76, such as the drivetrain batteries, as well as a control and telemetryinterface 102 for communicating, such as via a motor controller 104,with the off board motor(s), such as drivetrain motors 78. Further, theprocessor 90 may include a diagnostic port 106 for facilitatingtroubleshooting or other maintenance operations for the docking fixture14 a and the energy supply module 16 a connected thereto. Additionally,the processor 90 of the docking fixture 14 a may be in communicationwith the vehicle management system 108.

Although one embodiment of an energy supply module 16 a and associateddocking fixture 14 a is depicted in FIG. 4 and described above, thisembodiment is provided for purposes of illustration and is merely oneexample with such modules 16 and associated docking fixtures 14 beingconfigured in different manners in other embodiments depending upon thetype of module 16 and the type of communication and control desired withrespect to the module 16. In any event, the docking fixture 14 isconfigured to communicate with the module 16, such as via datacommunication, power communication and/or fluid communication, and, inturn, interface the module 16 with other modules or other componentseither onboard or off board the modular vehicle 10.

In order to facilitate the removable connection of a module 16 to adocking fixture 14, the docking fixture 14 and the module 16 may includeone or more of an electrical power connection, a fluid connection and adata communication connection. With respect to the embodiments of theenergy supply module 16 a and associated docking fixture 14 a depictedin FIG. 4, the energy supply module 16 a and the docking fixture 14 aeach includes a plurality of electrical power connections, a pluralityof data communication connections and a fluid connection. Although themanner in which the connections may be made may widely vary withoutdeparting from the spirit and scope of the present disclosure, thedocking fixture 14 a of one embodiment for facilitating removableconnection with a energy supply module 16 a, such as shown in FIG. 4, isdepicted in FIGS. 5A-5C. As shown in FIG. 5A, the docking fixture 14 amay include first and second fluid connections 110 that serve to supplycooling fluid to the energy supply module 16 a and that serve to receivecoolant from the energy supply module 16 a following circulationtherethrough. While the fluid connections 110 may be configured invarious manners, the fluid connections 110 of one embodiment are quickdisconnect fluid connections. The docking fixture 14 a of theillustrated embodiment also includes electrical power connections 112for permitting high voltage and low voltage signals to be transmittedbetween the energy supply module 16 a and the docking fixture 14 a.Further, the docking fixture 14 a of the illustrated embodiment mayinclude a plurality of data communication connection 114, such as theplurality of seven-pin connectors depicted in FIG. 5A. However, both theelectrical power connections and the data communication connections canbe constructed in different manners in other embodiments of the presentdisclosure. For example, the data communication connections may beCANbus connections, 422 connections, 232 connections or the like. Tofacilitate the robust nature of the modular vehicle 10, the dockingfixture 14 a may include an environmentally sealed interface 116surrounding the electrical power connections 112 and the datacommunication connections 114. Additionally, the docking fixture 14 amay include one or more guide pins 118 for facilitating connection withthe respective module 16 in an aligned manner. As will be understood,the energy supply module 16 a may also include corresponding electricalpower connections, fluid connections and data communication connectionsto mate with the respective connections of the docking fixture.Additionally, the energy supply module 16 a may include holes positionedinside so as to receive the guide pins 118, thereby aligning the module16 with the docking fixture 14.

As shown in FIGS. 5B and 5C, the docking fixture 14 may also includeconnections to other components. For example, the docking fixture mayinclude a thermal docking port 120 including additional fluidconnections for connection to an external radiator and pump 86. In thisregard, the thermal docking port 120 may include a first fluidconnection for receiving coolant from the radiator and pump 86 and asecond fluid connection for returning coolant to the radiator and pump86 following circulation through the energy supply module 16 a.Additionally, the docking fixture 14 may include a motor power port 122including one or more electrical power connections for providing powerto an external motor, such as a drivetrain motor 78.

As noted above, the modular vehicle 10 may include any number of modules16 of the same type. For example, the modular vehicle 10 may include twoor more energy supply modules 16 a with each energy supply module 16 abeing connected in parallel to a respective docking fixture 14 a. Byincluding a selectable number of modules 16 of the same type, such asenergy supply modules 16 a, the capacity and performance characteristicsof the modular vehicle 10 may be individually tailored. For example, amodular vehicle 10 having multiple energy supply modules 16 a may becapable of providing more power in anticipation of deployment inscenarios requiring greater power, while other modular vehicles 10having a single energy supply module 16 a may be intended to be deployedin scenarios anticipated to require lower power levels.

By way of example, FIG. 6 depicts two energy supply modules 16 aremovably connected to respective docking fixtures 14 a. As will beapparent, each pair of energy supply modules 16 a and docking fixtures14 a is of the type depicted in FIG. 4 and described above. However, thedocking fixtures 14 a are connected to one another, such as via aparallel port interface 130, so as to facilitate the transmission ofdata, power and/or coolant therebetween. Although the interface 130between the docking fixtures 14 a may vary, the docking fixtures 14 a ofthe illustrated embodiment include data communication connections, suchas to provide data from the processor 90 of the docking fixture 14 aand/or the processor 40 of the associated energy supply module 16 a tothe other docking fixture 14 a. In the illustrated embodiment, forexample, the discrete inputs and outputs and the control and telemetryinterface 102 are connected to the other docking fixture 14 a.Additionally, the high voltage power bus 68 and/or the coolant or otherfluid may be shared between the docking fixtures 14 a for redundancy,reliability or other purposes. The docking fixtures 14 a may operate inconcert and, in one embodiment, one of the docking fixtures may beidentified to be the master docking fixture with the other dockingfixture being identified to be a slave docking fixture. In thisembodiment, the master docking fixture can at least partially controlthe operation of the slave docking fixture.

Although the parallel port interface 130 between the docking fixtures 14a may be provided in various manners, the docking fixture 14 aillustrated in FIGS. 5A-5C may include an expansion port 132 tofacilitate interconnection with another docking fixture 14 a, therebyproviding for a parallel port interface 130. In the illustratedembodiment, the expansion port 132 includes electrical power connectionsand data communication connections. However, the expansion port 132 mayalso include one or more fluid connections, if so desired. In order tofacilitate a further connection with an additional docking fixture, thedocking fixture 14 a depicted in FIGS. 5A-5C may include additionalexpansion ports, such as on opposite sides of the housing.

From a mechanical standpoint, the docking fixtures 14 a and the chassis12 may include complimentary rails and a rail interface for facilitatingmounting of the docking fixtures 14 in a predefined location relative tothe chassis 12. In addition, by utilizing a rail or other elongatemounting structure, multiple docking fixtures 14 may be mounted to thesame rail or other mounting structure so as to facilitate the alignedrelationship of the docking fixtures 14 such that those docking fixtures14 that are disposed in a parallel configuration may be more readilyinterconnected. For example, FIG. 5C depicts a rail 134 on which thedocking fixture 14 a may be mounted.

One example of a docking fixture 14 a to be used with an energy supplymodule 16 a is depicted in FIGS. 5A-5C and is described above. However,as noted, the docking fixture 14 may have other configurations dependingupon the type of connections to be made, the type of module 16 withwhich the docking fixture 14 will mate and the like. As another example,FIGS. 7A and 7B illustrate a docking fixture 14 c for an energy storagemodule 16 b. As shown in this instance, the docking fixture 14 cincludes multiple fluid connections 140 for facilitating fluidcirculation between the energy storage module 16 b that would beremovably connected to the docking fixture and an external radiator 18or other source of coolant or other fluid. Additionally, the dockingfixture 14 c includes a plurality of electrical power connections 142and a plurality of data communication connections 144 disposed within anenvironmentally sealed interface 146 for connection with correspondingelectrical power connections and data communication connections of anenergy storage module 16 b.

A modular vehicle 10 may include a plurality of energy storage modules16 b arranged, for example, in parallel with each energy storage module16 b removably connected to a respective docking fixture 14 c. As such,the modular vehicle 10 may include a plurality of docking fixtures 14 cwith the docking fixtures 14 c interconnected to one another as depictedin FIG. 7C. In this regard, the docking fixtures 14 c may beinterconnected via a parallel port interface shown in FIGS. 7B and 7C,which may also include a plurality of electrical power connections 152,data communication connections 154 and fluid connections 150 tofacilitate circulation of fluid and power through the various dockingfixtures 14 c in a controlled fashion. In order to facilitate thealignment of a docking fixture 14 c with a corresponding energy storagemodule 16 b, the docking fixture 14 c may include one or more guide pins148 and/or one or more guide pin holes for mating with correspondingguide pin features of the respective energy storage modules 16 b. Inaddition, the docking fixtures 14 c can include guide pins 156 and/orguide pin holes for mating with corresponding guide pin features ofother docking fixtures 14 c to facilitate the parallel alignment andinterconnection of adjacent docking fixtures 14 c. In order to furtherfacilitate alignment of the docking fixtures 14, the chassis 12 mayinclude one or more mounting rails 158 and the docking fixtures 14 mayinclude a corresponding mounting structure 160 that is received withinand engaged by the mounting rails 158 as shown, for example, in FIG. 7C.As such, the mounting rails 158 and associated mounting structure 160facilitate the aligned positioning of the docking fixtures 14 and thesecure affixation of the docking fixtures 14 to the chassis 12.

By utilizing a modular approach, different combinations of modules 16including different types of modules 16 and different numbers of thesame type of modules 16 may be mounted to the same type of chassis 12,therefore adapting the resulting modular vehicles 10 to the anticipatedoperational characteristics to be demanded of the modular vehicles 10following deployment. By relying upon a modular approach with themodules 16 being removably connected to corresponding docking fixtures14, the modules 16 may be more readily replaced so as to accommodateimprovements in technology, repair and changes in the operationalcharacteristics to be demanded of the modular vehicle 10. As notedabove, the modular vehicle 10 may include any number of energy supplymodules 16 a to supply a modular vehicle 10 with different levels ofpower. While the plurality of energy supply modules 16 may all be at thesame type, the modular vehicle 10 of one embodiment may includedifferent types of energy supply modules including both combustiongenerator modules and electrical power generation modules so as toprovide customizable hybrid vehicles. Additionally, by includingcontrollers within each module 16 and docking fixture 14, the modules 16and docking fixtures 14 may be individually managed while taking intoaccount the operation of other related modules 16 so as to provide forefficient operation.

As illustrated in FIG. 8, a modular vehicle 10 may therefore be readilyconstructed by providing a chassis 12 that carries a plurality ofdocking fixtures 14. See operation 200. As described above, the dockingfixtures 14 may include one of more of an electrical power connection, afluid connection and a data communication connection. Thereafter, aplurality of modules 16 may be removably connected to respective dockingfixtures 14. See operation 202. These modules may include an energysupply module 16 a and an energy storage module 16 b. In one embodiment,the modules also include a cooling module. In order to removably connectthe plurality of modules 16 to respective docking fixtures 14, anelectrical power connection of at least one of the modules 16 may becoupled to the electrical power connection of at least one dockingfixture 14. See operation 204. In addition, a fluid connection of atleast one of the modules 16 may be coupled to the fluid connection of atleast one docking fixture 14. See operation 206. And, the datacommunication connection of at least one module 16 may be coupled to thedata communication of at least one docking fixture 14. See operation208. Thereafter, one or more loads, such as crew compartment loads,external power consumption loads, etc., may be connected to the modules16 via the docking fixtures 14. See operation 210. As such, the modularvehicle 10 may be readily constructed having operational characteristicsthat may be tailored to the anticipated deployment scenario, therebyresulting in a modular vehicle 10 that is capable the desiredperformance, but that may deliver such performance in an efficientmanner.

Many modifications and other embodiments of the disclosure set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

That which is claimed:
 1. A method of constructing a modular vehicle comprising: providing a chassis that carries a plurality of docking fixtures, wherein at least one of the docking fixtures comprising an electrical power connection, at least one of the fixtures comprising a fluid connection, and at least one of the fixtures comprising a data communication connection; and removably connecting a plurality of modules to respective ones of the docking fixtures, wherein the plurality of modules comprise at least an energy supply module and an energy storage module, and wherein removably connecting the plurality of modules comprises coupling an electrical power connection of at least one of the modules to the electrical power connection of at least one docking fixture, coupling a fluid connection of at least one of the modules to the fluid connection of at least one docking fixture, and coupling a data communication connection of at least one of the modules to the data communication connection of at least one docking fixture.
 2. A method according to claim 1 wherein removably connecting a plurality of modules to respective ones of the docking fixtures further comprises facilitating removable connection of at least one module to a respective docking fixture with at least one guide pin.
 3. A method according to claim 1 wherein removably connecting a plurality of modules to respective ones of the docking fixtures further comprises coupling a fluid connection of a cooling module to the fluid connection of a respective docking fixture.
 4. A method according to claim 1 further comprising sharing a common fluid between the plurality of docking fixtures and the plurality of modules.
 5. A method according to claim 1 wherein removably connecting a plurality of modules to respective ones of the docking fixtures further comprises removably connecting a crew compartment load to a respective docking fixture.
 6. A method according to claim 1 wherein removably connecting a plurality of modules to respective ones of the docking fixtures further comprises removably connecting an external power consumption load to a respective docking fixture.
 7. A method according to claim 1 wherein the energy supply module comprises a fuel cell.
 8. A method according to claim 1 further comprising providing for data communication via the respective electrical power connections of the at least one docking fixture and the at least one module.
 9. A method of constructing a modular vehicle comprising: providing a chassis; providing a plurality of docking fixtures carried by the chassis with each docking fixture comprising at least one of an electrical power connection, a fluid connection and a data communication connection; connecting an energy supply module to a respective docking fixture, the energy supply module comprising an electrical power connection coupled to the electrical power connection of the respective docking fixture and a data communication connection coupled to the data communication connection of the respective docking fixture; connecting an energy storage module to a respective docking fixture, the energy storage module comprising an electrical power connection coupled to the electrical power module of the respective docking fixture; and connecting a cooling module to a respective docking fixture, the cooling module comprising a fluid connection coupled to the fluid connection of the respective docking fixture.
 10. A method according to claim 9 wherein at least one of the docking fixtures, energy supply module, energy storage module or cooling module further comprises at least one guide pin for facilitating removable connection of the docking fixture and a respective module.
 11. A method according to claim 9 further comprising sharing a common fluid between the plurality of docking fixtures, the energy supply module and the cooling module.
 12. A method according to claim 9 further comprising providing a crew compartment load.
 13. A method according to claim 9 further comprising providing an external power consumption load.
 14. A method according to claim 9 wherein the energy supply module comprises a fuel cell.
 15. A method of constructing a modular vehicle comprising: providing a chassis that carries a plurality of docking fixtures, wherein at least one of the docking fixtures comprising an electrical power connection, at least one of the fixtures comprising a fluid connection, and at least one of the fixtures comprising a data communication connection; and removably connecting a plurality of modules to respective ones of the docking fixtures, wherein the plurality of modules comprise at least an energy supply module and an energy storage module, wherein the energy supply module comprises a fuel cell, wherein the plurality of modules comprise at least one of a crew compartment or a power consumption load, and wherein removably connecting the plurality of modules comprises coupling an electrical power connection of at least one of the modules to the electrical power connection of at least one docking fixture, coupling a fluid connection of at least one of the modules to the fluid connection of at least one docking fixture, and coupling a data communication connection of at least one of the modules to the data communication connection of at least one docking fixture.
 16. A method according to claim 15 wherein removably connecting a plurality of modules to respective ones of the docking fixtures further comprises facilitating removable connection of at least one module to a respective docking fixture with at least one guide pin.
 17. A method according to claim 15 wherein removably connecting a plurality of modules to respective ones of the docking fixtures further comprises coupling a fluid connection of a cooling module to the fluid connection of a respective docking fixture.
 18. A method according to claim 15 further comprising sharing a common fluid between the plurality of docking fixtures and the plurality of modules.
 19. A method according to claim 15 further comprising providing for data communication via the respective electrical power connections of the at least one docking fixture and the at least one module. 